Difference between revisions of "Locator Tutorial: Setting up Locator to work with YASKAWA robots"

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Revision as of 08:56, 4 March 2019

NOTE: Users are strongly recommended to read the general introduction to robot interfaces prior to installing specific robot modules.

1. Prerequisites

Prior to setup, please ensure that your Yaskawa controller meets the following criteria:

- YRC1000 - the latest controller version. FS100, DX100 and DX200 are currently not supported but available on demand. NX100 is deprecated!

- MotoPlus Runtime option - This option needs to be enabled on robot controller in order to get Photoneo Yaskawa interface up and running.

The Photoneo Yaskawa Interface was originally developed using GP8 manipulator and YRC1000 Controller with the following firmware version:


Alt text
Figure 1.0.1

2. Yaskawa Controller Setup

2.1 Maintenance & Management Mode

Start the Robot Controller into a Maintenance Mode by holding the Main Menu button while turning the main switch on.

You should hear a short beep during the boot. Maintenance mode screen is shown in the figure below:


Alt text
Figure 2.1.1


Switch Security Level from Editing to Management Mode. Browse to System -> Security and select Management Mode:


Alt text
Figure 2.1.2


Password to management mode is 9999999999999999 (16x9):


Alt text
Figure 2.1.3


Notice three keys in the top status bar - this means - Management Mode is Active.

2.2 Set IP Address

Configure the IP address of the robot controller. In Maintenance mode, browse to System -> Setup -> Option Functions:


Alt text
Figure 2.2.1


Select LAN Interface Setting to enter the Network Configuration pane:


Alt text
Figure 2.2.2


Select Manual Setting for LAN2 Port and amend the IP Address to meet your network requirements:


Alt text
Figure 2.2.3


NOTE: It is recommended to plug Ethernet cable to the LAN2 port and try to ping Robot Controller from a PC to validate proper network configuration.

2.3 Enable MotoPlus Functionality

If MotoPlus functionality has not been enabled on robot controller before, browse to System -> Setup -> Option Functions

Switch MOTOPLUS Func State from NOT USED to USED.


Alt text
Figure 2.3.1


MotoPlus APL icon should now become visible on the left pane.

Enter the MotoPlus Func. Settings and enable MotoPlus autostart option:


Alt text
Figure 2.3.2

2.4 Load MotoPlus Application

ZIP Archive of Photoneo Yaskawa Locator Module contains several JOB files and single PhotoneoLocatorModule.out file.

The OUT file is a MotoPlus binary and needs to be loaded to the Robot Controller in Maintenance Mode.

Select MOTOPLUS Apl. -> Load (User Application) and select the PhotoneoLocatorModule.out file.


Alt text
Figure 2.4.1


Confirm loading the MotoPlus application by clicking YES:


Alt text
Figure 2.4.2


Maintenance mode part of the configuration is finished now. Restart the Robot Controller into Normal Mode. No error should appear after the reboot.

3. Photoneo Yaskawa Module Setup

3.1 Copy INFORM JOBS to Robot Controller

As a next step, copy all JOBS from INFORM Folder of ZIP Archive to the robot controller. Use USB or SD Card for transfer.

Browse to Ex. Memory -> Load and select all available JOBS as shown in the figure below:


Alt text
Figure 3.1.1


Hit Enter to start the transfer:


Alt text
Figure 3.1.2


All JOB files are now available in the Robot Controller. Before proceeding further, it is important to understand variable mapping.


3.2 Variable Mapping

Photoneo Yaskawa Module occupies following data registers:

BYTE REGISTERS (FLAGS):

  • B000 - CONNECT_TO_VC - flag set by INFORM JOB to issue MotoPlus application to establish connection to VC
  • B001 - CONNECTED - flag set by MotoPlus application to notify INFORM that connection has been established
  • B002 - NEW_REQ - flag set by INFORM JOB to notify MotoPlus application that new request has been issued
  • B003 - REQ_FINISHED - flag set by MotoPlus application to notify INFORM that request has been handled
Alt text
Figure 3.2.1


INTEGER RESIGTERS:

  • I000 - VC_IP_ADDRESS_1 - First Part of Vision Controller IP Address
  • I001 - VC_IP_ADDRESS_2 - Second Part of Vision Controller IP Address
  • I002 - VC_IP_ADDRESS_3 - Third Part of Vision Controller IP Address
  • I003 - VC_IP_ADDRESS_4 - Fourth Part of Vision Controller IP Address
  • I004 - LOCATOR_PORT - Locator Port as configured in Locator GUI
  • I005 - TOOL_ID - TCP ID which should be used for picking
  • I006 - REQUEST_TYPE - type of request SINGLE/MULTIPLE/DISCONNECT
  • I007 - LOCATOR_STATUS - The result of last trigger OK/TIMEOUT/ERROR
  • I008 - NUM_OF_REQ_TAR - Number of targets requested by Locator
  • I009 - NUM_OF_REC_TAR - Number of targets localized and transfered by Locator
  • I010 - CURRENT_PICK_ID - Used only in multiple result mode as a counter of picked objects


Alt text
Figure 3.2.1


POSITION REGISTERS:

  • P000 - Approaching offet value
  • P001 - P100 - Reserved for Locator results
  • P101 - Used for calculating approach pose for current pick (P000 + P00X)

3.3 Setting IP Address of Locator

Locator Client running on the robot controller requires information about the IP Address of Vision Controller (Locator Server) in order to establish a successful connection.

Four integer registers (I000 - I003) are utilized for this purpose. Insert current IP Address of Vision Controller (Locator Server) here:


Alt text
Figure 3.3.1


4. Calibration

Robot Camera Calibration is a crucial step in Locator configuration. Accurate calibration guarantees that object positions will be calculated directly in Robot Base coordinates.

Robot - Camera Calibration

Mount the Scanner firmly, ensure that the scene is properly captured from the final position and start the Photoneo Robot Camera Calibrator:


KUKA SettingUp Guide Scanner Calibration 10.png


Recommended procedure to configure the tool is to select a new tool configuration, with all parameters set to zero. In our case it was STANDARD TOOL, which was the first tool on selection. It is necessary to complete the whole calibration process with the selected tool (no changing). You can double-check this by looking at upper right corner icon, showing the number of the used tool.


Tool selection before calibration edit.jpg


Connect to the Scanner, select XYZ EXTRINSIC (Standard for YASKAWA robots), adjust the Sphere radius (21.75 mm in this case/ 20.00 mm for a standard ping-pong ball) and set the Min visible parameter to 40%:


Yaskawa calibration first menu edited.png


Attach a ping-pong ball to the gripper and jog the robot to the first position (usually the nearest corner of the bin/ area of interest).


To get current robot tool positions, you have to go through ROBOT -> CURRENT POSITION . In the windows, select the correct tool.


Robot Curent Tool Position Locator.jpg


Input the X,Y,Z [mm] and Rx, Ry, Rz [deg] values of the current position to the first line of the point list and repeat the same procedure for at least 7 more points.

The recommended procedure is to cover the four corners + four positions in the center of the scanning volume.

Change the orientation of the tool in all axes to achieve a wider range of input values. Press the Compute button once you have added the final point.

For successful calibration, the Final Error per point should not exceed 2-3 mm. (0.869 in this example).


Succsesful calibration edited.png


If the final error value is too high, try adding more points or start the calibration from the beginning again. Increasing the orientation of the tool can help to reduce the final error value.

Once you are satisfied with the results, press the Set Matrix to PhoXi button to store the results to the PhoXi Scanner.


Send To Phoxi Edited.png


Do not forget to switch the Coordinate Space in PhoXi Control after calibration has been completed successfully:


Screenshot from 2019-03-01 14-45-48.png


In addition to the Robot - Camera transformation matrix, the calibration process also calculates a Calibration Sphere Misplacement vector which denotes the transformation between the selected Tool ,and the center of the sphere (the ping-pong ball). This information can be used for calibration verification. First Set the YASKAWA Tool coordinates according to the Misplacement Vector as calculated in the calibration process. This is done in the TOOL menu. Ensure that the ping-pong ball has not moved since the end of calibration.


After calibration misplacement vector set.jpg


The values calculated by the Photoneo Robot Camera Calibration Tool , and current robot tool position ,should approximately match.

INFORM

The Locator Yaskawa module is a combination of the MotoPlus background routine and several INFORM Jobs.

  • - LocatorModule_v_X_Y_Z.out - handles communication with Locator and feeds position registers with received data
  • - PHO_MAIN_SINGLE.JB - is a basic template for using Locator Yaskawa Module in the Single Result Mode - Reteach Home Position Here
  • - PHO_MAIN_MULTIPLE.JB - is a basic template for using Locator Yaskawa Module in the Multiple Result Mode - - Reteach Home Position Here
  • - PHO_GRIPPER_ATTACH.TP - users should assign commands required for attaching object to the gripper to this function
  • - PHO_GRIPPER_DETACH.TP - users should assign commands required for detaching object from gripper to this function
  • - PHO_PICK_TARGET
  • - PHO_PLACE_TARGET

Communication protocol

Following figures explain Locator-YASKAWA communication protocol in both Single and Multiple Result Modes:


Locator YASKAWA Single Result Mode.png


Locator YASKAWA Multiple Result Mode.png